Silicone optics

ABSTRACT

Silicone-containing light fixture optics. A method for manufacturing an optical component may include mixing two precursors of silicone, opening a first gate of an optic forming device, moving the silicone mixture from the extrusion machine into the optic forming device, cooling the silicone mixture as it enters the optic forming device, filling a mold within the optic forming device with the silicone mixture, closing the first gate, and heating the silicone mixture in the mold to at least partially cure the silicone. Alternatively, a method for manufacturing an optical component may include depositing a layer of heat cured silicone optical material to an optical structure, arranging one or more at least partially cured silicone optics on the layer of heat cured silicone optical material, and heating the heat cured silicone optical material to permanently adhere the one or more at least partially cured silicone optics to the optical structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation patent application of U.S.application Ser. No. 14/275,177, filed May 12, 2014, which claims thebenefit of U.S. Provisional Application Ser. No. 61/855,207 filed May10, 2013, each of which is incorporated by reference.

FIELD OF THE INVENTION

Embodiments of the present invention relate to silicone optics for alight source, such as a light emitting diode (LED) and methods of makingsame.

BACKGROUND

Electrical lighting and associated light fixtures, or luminaires, aresignificant sources of energy consumption implicating both environmentaland energy cost concerns. Based on estimates by the U.S. Department ofEnergy (DOE), lighting represents 40% of the electrical consumption in atypical commercial building. U.S. Lighting Energy Policy is movingtowards increased efficiency in order to lower green-house gas emissionsand energy use. Increasing efficiency through maximizing light outputwhile minimizing losses associated with reflecting light in unwanteddirections are a focus of the lighting industry. In addition toemploying high efficiency light sources, such as light emitting diodes(LED), high efficiency reflectors and lenses are necessary.

There is a need for a long, thin, and optically detailed lens that isnominally 48″ to 96″ long that is typically used in indoor, industrial,or specialty luminaires. The cost of the tool required to injection moldthis size optic lens is extremely high, typically more than $350,000 in2013. Also the size and weight (typically thousands of pounds) of thetool makes it difficult to handle and to transport the tool from storageto the molding machine. The large size of such a tool limits the typeand size of injection molding machines with which such a tool can beused. Only the industry's largest machine can support this size of tool,and part costs increase due to the overhead of running such a large tooland machine, making it difficult to justify this method of opticmanufacture for use in an economy class luminaire because the lens costbecomes prohibitive.

It is possible to extrude such lenses (typically formed from a polymericmaterial such as acrylic), provided they have a uniform profile.However, it is difficult to extrude acrylic poly(methyl methacrylate)(PMMA)/polycarbonate (PC) optical lenses having a flat surface with highpolish and with no extruding lines that cause optical striations in thedistribution. Moreover, it is also difficult to successfully extrudelenses having thick to thin parts (i.e., some parts of the lens profileare thicker than other parts of the lens profile) because of theinconsistency of polymerization, cross-linking, or curing of such lenses(i.e., the thicker parts take longer to cool and harden) which can leadto unwanted shrinkage, deformation, or distortion of the opticaldistribution. Furthermore, these problems also reduce the opticalefficiency. Extrusion machines have limits on the size and thick to thinratio that they can handle and extrude properly in order to produce auseable part. Such limitations limit the available opticaldistributions, and some desired distributions may not be possible.Moreover, limitations inherent in the manufacturing process of glass andplastic lenses render it extremely difficult to incorporate fine detailand small-scale features in the optics.

SUMMARY

In some aspects, a method for manufacturing an optical component caninclude mixing two precursors or portions of silicone where the twoportions may be, for example, (1) a base and a curing agent or (2) anunpolymerized or partially polymerized resin and a crosslinking reagent.The method may also include moving the silicone mixture from theextrusion machine into an optic forming device, cooling the siliconemixture as it enters the optic forming device, extruding the siliconemixture through a die, heating the silicone mixture as it passes throughthe die to cure the silicone mixture into the optical component, andcutting the optical component at a desired length.

Alternatively, the method can include mixing two portions of silicone(or precursors), opening a first gate at an upstream end of an opticforming device, moving the silicone mixture from the extrusion machineinto the optic forming device, cooling the silicone mixture as it entersthe optic forming device, filling a mold within the optic forming devicewith the silicone mixture, closing the first gate, and heating thesilicone mixture in the mold to at least partially cure the silicone.

Furthermore, a method is provided that includes applying a layer of heatcured silicone optical material on an optical structure, arranging oneor more at least partially cured silicone optics on the layer of heatcured silicone optical material, and heating the heat cured siliconeoptical material to permanently adhere the one or more at leastpartially cured silicone optics to the optical structure.

In other aspects, an apparatus for manufacturing an optical component isprovided. The apparatus may include an extrusion machine with one ormore inputs for supplying at least two portions of silicone (orprecursors) to the extrusion machine such that the at least two portionsof silicone combine to form a silicone mixture, an optic forming deviceconnected to a downstream output of the extrusion machine such that theoptic forming device mounted on a tool platform and configured toreceive the silicone mixture from the extrusion machine, a cooling unitattached to the optic forming device adjacent to the interface with theextrusion machine, and a heating unit attached to the optic formingdevice.

These and other aspects, features and advantages of the presentinvention may be more clearly understood and appreciated from a reviewof the following detailed description and by reference to the appendeddrawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view depicting an apparatus for manufacturing anoptical component.

FIG. 2 is a more detailed schematic view depicting the apparatus formanufacturing an optical component of FIG. 1.

FIG. 3 is a schematic view depicting a separable mold for an apparatusfor manufacturing an optical component.

FIG. 4 is a schematic view depicting a non-separable mold for anapparatus for manufacturing an optical component.

FIG. 5 depicts a multiple-component optic.

FIG. 6 is a perspective view of an optic formed with a second element atleast partially encapsulated therein.

FIG. 7 is a cross-sectional view of the optic of FIG. 6.

FIG. 8 is a perspective view of an optic formed with two second elementsat least partially encapsulated therein.

FIG. 9 is a cross-sectional view of the optic of FIG. 8.

FIG. 10 is a perspective view of a multiple-component discrete optic.

FIG. 11 is a cross-sectional view of the optic of FIG. 10.

FIG. 12 is an exploded view of a multiple-component discrete optic.

FIG. 13 is a perspective view depicting an exploded wireframe and linedrawing views of a multiple-component discrete optic.

FIGS. 14A and 14B are perspective and cross-sectional views,respectively, of an optic.

FIG. 15 is a cross-sectional view of an optic assembly.

FIG. 16 is a schematic view of a light fixture assembly including anoptic assembly.

FIGS. 17A, 17B, and 17C depict front, side, and underneath views of alight pattern produced from an optic.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

Embodiments of the present invention provide an optic formed at leastpartially of moldable silicone. Various types of silicone materialshaving the properties described herein are available from Dow Corning(“Dow”). Dow's MS-1002 moldable silicone may be useful in certainapplications. However, other sources for moldable silicone materials areknown or readily identified by those skilled in the art.

Such optics may be formed by a variety of methods or combinations ofmethods, including extrusion and casting/molding. Embodiments of themethods contemplated herein use an extrusion machine to form the optic.Traditional extruder systems include an extrusion machine that deliversthe molten polymeric lens material (e.g., acrylic) to an extruding dieand then on to a separate shaping die that imparts the final lens shape.The lens material is exposed to air as it moves between the extrudingdie and the shaping die, which accelerates cooling and thus curing(particularly the outer surface) of the material between the extrudingdie and the shaping die. Thus, as the material is fed through theshaping die, the die tends to scrape the hardened outer surface or shellof the partially-formed optic, thereby causing undesirable striationsextending along the length of the final optic.

Optical pattern molding may include partially or fully encapsulating asecond optical component constructed from a second material such asglass or another optical material (the second optical component may be aprinted circuit board or a reflector) within a silicone first opticalstructure through an injection mold process machine co-molding the partstogether to form a single device with multiple optical structurecomponents. The resultant device can include mechanical features orstructures for mounting, sealing, or may include textures or patterns toocclude the view through the mechanical structure.

Extruding and Casting Methods

Embodiments of the methods contemplated herein combine an extruding dieand shaping die into a single optic forming device having a die or moldtherein for forming the optic with the desired geometry. Embodiments ofthis system are shown in FIGS. 1-4. The optic forming device is alsoprovided with heating/cooling elements to cure the silicone and therebyset it in the desired shape.

As shown in FIG. 2, moldable silicone may be formed from two liquidcomponents combined to form a liquid that is heated to a curingtemperature at which the silicone becomes solid. The first part 210 aand the second part 210 b may be, for example, (1) a base and a curingagent or (2) an unpolymerized or partially polymerized resin and acrosslinking reagent. While the pre-cured viscosity of silicone canvary, in some embodiments, it has a viscosity similar to water. Inmethods contemplated herein, the first and second parts 210 a and 210 bare moved from the extrusion machine 201 to the optic forming device202. The optic forming device may be mounted on a tool platform 203.Very little pressure is required to deliver the silicone into the opticforming device given its low viscosity. Cooling elements 204 proximatethe entry point into the optic forming device to ensure that thesilicone does not cure too quickly but rather remains in liquid form forextruding and/or casting/molding.

The optic forming device 202 includes an extrusion mechanism to extrudethe silicone optic. After the silicone enters the optic forming device,it is extruded through a die 206. Heating elements 205 provide heat tocure the silicone. In this way, a silicone optic can be continuouslyextruded using the optic forming device 202 and subsequently cut intothe desired lengths.

As shown in FIG. 3, in an alternative embodiment, the optic formingdevice 202 includes a mold 301. The liquid silicone flows into the mold,and, due to its low viscosity, it fills the mold completely leaving nogaps or shrinkage. The mold 301 may include locating pins 302 andcorresponding holes 303. The heating elements 205 cure the silicone inthe mold 301.

In some embodiments, this casting process is a one shot process wherethe mold has the precise dimension and geometry of the desired optic.Silicone is injected into the mold through a first gate at an upstreamend of the mold and is cured in the mold (e.g., see FIG. 4). The mold isthen opened, the optic removed, the mold closed again, and the processrepeated so as to form additional, discrete optics. In otherembodiments, as depicted in FIG. 3, the mold is formed by a first halfmold 301 a and a second half mold 301 b, at least one of which ismoveable relative to the other such that the two halves can be heldtogether by a clamp 304. After the silicone optic is cured in the mold,the two half molds are separated to open the mold 301 and allow themolded part to be removed. The mold 301 is then closed again and theprocess repeated. This process can permit over-molding silicone ontoother existing or previously formed components (including pre-molded orcast materials) such as glass, metals, plastics, printed circuit boards,materials with optical properties such as a reflector, or a mechanicalfastener device to mount the optic in a luminaire, as discussed in moredetail below. This process may also be used to over mold several timesto build up the desired optical distribution or properties. Moreover, itis also possible using this method to form features (e.g., ribs, etc.)on the optic that are discretely located on the optic (i.e., notcontinuous) or that do not extend parallel to the extrusion directionand thus are not able to be formed using the extrusion process discussedabove. Such features may be desirable (but not required) to control thedistribution of light parallel to the length of the optic.

The curing process may be limited to a maximum curing temperature. Inparticular, when a silicone optic is co-molded with a second componentthat is temperature-sensitive. For example, when co-molding a siliconepart with a silicone optic with a circuit board with solderedconnections, a maximum curing temperature of 105° C. may be established.

In an alternative embodiment, the optic forming device 202 includes amold 401 that can produce a continuous optic that includes multipleadjacent segments which are formed sequentially. As shown in FIG. 4,after an optic is at least partially cured in a mold 401, it may bemoved longitudinally from the mold 401 so as to allow additionalsilicone material to fill the mold through the first gate 402 behind itfor a repeated process. For example, a second gate 403 may be providedat the downstream end of the mold. After the optic is formed, the secondgate 403 may be temporarily opened to permit at least a portion of themolded optic to move from the mold, after which, if necessary ordesirable, the second gate 403 may be closed again (or partially closed)and the process repeated. The molded optic can be moved from the moldusing a variety of methods, including fluid pressure. Fluid may beinjected adjacent to the first gate 402 to move the at least partiallycured optic toward the second gate 403. The fluid used to move the opticthrough the mold may be a liquid or a gas including, for example, water,air, argon gas, carbon dioxide, or any inert gas. The optic can beformed having any practical length and subsequently cut to length orseparated as needed to produce a part, for example, 24″, 48″, or 96″long.

Using fluid to propel the optic is advantageous compared to othermethods known to the art such as ejector pins. Ejector pins typicallyleave large witness lines and create images on the surface along theoptic, often in several locations, which is not desirable for opticalperformance. When using pressurized fluid, the fluid can be expelledfrom one location along the optic (unlike several ejector pins known tothe art) such that the fluid creates a ripple effect along the opticalsurface where the fluid moves and or removes the optic from the mold.The ripple effect is caused by injecting fluid at one end of the tool atthe surface of the optical finish where the silicone contacts the mold.This forceful injection of fluid through pneumatics or hydraulicscompresses the silicone part in the mold, creating a small bubble at theinterface between the surface of the mold and the silicone optic partthat propagates along the part to the opposite end of the tool, causingthe part to break free from the mold and begin moving to facilitate atransition to another stage of the process for additional over molding,continuous molding, or removal of the part all together from the mold.

The silicone is heat cured and initially forms a shell at the opticsurface. Because silicone has no significant expansion/contractiondifferential, curing of the inner part of the optic after the outer partis cured does not distort the outer shell. Thus, it is possible to moldvery complex and detailed optics with high thick to thin ratios usingsilicone. It is also possible to remove the silicone optic from theoptic forming device before it is completely cured to increaseproduction efficiency. Rather, the silicone can be sufficiently cured inthe optic forming device to be self-supporting and then removed from theoptic forming device. The partially-cured optic can be set aside orfurther heated to realize full cure without distorting the shape of theoptic.

Embodiments of optics contemplated herein can include linear optics orround or otherwise discrete optics. Such optics may be formed by theprocesses described above or by other processes known in the art.

A continuous linear optic may be formed entirely of silicone. The opticmay be formed of any length. In some embodiments, the optic is slim inwidth compared to its length. In some embodiments, the optic length isbetween 24″ and 96″ long, inclusive.

A silicone optic may also be extruded or cast/molded onto an existing orpreviously formed component (including pre-molded or cast materials)such as glass, metals, plastics, printed circuit boards, materials withoptical properties such as a reflector, or a mechanical fastener deviceto mount the optic in a luminaire. For example, FIG. 5 illustrates anoptic formed by co-extruding two brackets 501, a first previously formedcomponent 503, and a second previously formed component 504. A similararrangement could be created in a mold. The first previously formedcomponent 503 may be, for example, a phosphor lens and the secondpreviously formed component 504 may be, for example, a diffuser lens. Asilicone optic 505 is subsequently extruded or molded over the existingoptic. While not required, the illustrated silicone optic 505 may not beof consistent thickness but rather may have a high thick to thin ratioso as to better shape and control the light emitted from the optic. Theoptic may be designed to emit light in a single direction or in multipledirections.

Moldable silicone typically does exhibit room temperature vulcanizing(RTV), meaning that by its nature it does not tend to stick or otherwiseattach easily to other materials. Rather, mechanical retention may benecessary to attach some embodiments of the silicone optics disclosedherein to other structures. For example, structures or mechanicalfeatures such as voids (e.g., grooves, holes, etc.) may be provided inan existing structure over which the silicone is molded so that thesilicone fills the voids and, when cured, is mechanically interlockedwith the existing structure. FIG. 5 illustrates an embodiment in whichgrooves 502 are provided on one or both of the mounting brackets forthis purpose and the silicone fills the grooves to interlock thesilicone optic with the existing optic. Components with multiple layersof differing materials as shown in FIG. 5, may be constructed on arotary tool.

In an alternative embodiment, the optic 601 is formed with a reflector602 or other element at least partially encapsulated within it, as shownin FIGS. 6-9. For example, a reflector 602 may be positioned in a moldand the silicone material cast or molded to form the desired optic 601and so as to partially or entirely encapsulate the reflector 602. In theembodiment of FIG. 6, apertures 603 extend through a portion of thereflector body. When the silicone is cast around the reflector 602, itfills such apertures 603 so that, when cured, the silicone optic 601 ismechanically interlocked to the reflector body. As shown in FIGS. 6-9,the optic 601 may be extruded or cast/molded to include one or morerecessed areas to at least partially surround an adjacent component. Forexample, the optics shown in FIGS. 6-9 include a recessed area locatednear an adjacent component 604 where the adjacent component 604 may beone or more light sources.

Optic 601 typically may be up to 24 inches wide (i.e., the transversedirection in FIGS. 7 and 9) with a continuous length or any practicallength (i.e., the longitudinal direction in FIGS. 6 and 8). Further,modular sizes may be from 1 to 12 inches, 12 to 24 inches, 24 to 48inches, and 48 inches or longer for continuous run luminaires.

It may also be desirable, in some embodiments, subsequently to attach acured optic to another structure, such as (but not limited to) a printedcircuit board populated with one or more adjacent components 604 such aslight sources (the light source may be, for example, an LED). FIGS. 6-9illustrate embodiments of the optic 601 provided with a mounting flange605 or flanges that are partially encapsulated in the optic 601 but thatinclude an exposed portion (i.e., see mounting flange 605) that extendsfrom the optic 601. The exposed portion of the mounting flange 605 isprovided with apertures 603 to receive mechanical fasteners forattaching the optic 601 to another structure. In the figures, eachmounting flange 605 is shown formed integrally with a reflector 602 butsuch need not be the case. Moreover, in some embodiments, a reflector602 is provided without a mounting flange 605 and in other embodiments amounting flange 605 is provided without a reflector 602. Obviously manyother types of mountings structures (e.g., mounting brackets, etc.) canbe molded directly into the optic 601 and used to attach the optic 601to another structure. Embodiments are certainly not intended to belimited to the mounting flanges illustrated in the figures.

Methods for Discrete Lenses

Silicone optics need not be formed only as linear optics. Rather, thepresent disclosure related to silicone or other materials may also beused in forming discrete lenses. It can be difficult to manufacturediscrete lenses with the structure needed (e.g., with the necessarythick to thin ratio, etc.) to achieve a desired optical distribution. Insome embodiments, silicone may be used to enhance the optical propertiesof the lens. FIGS. 10-13 illustrate an embodiment of a round lens thathas an optic shell of a first material 1001 (e.g., glass, plastic, etc.in the figures). The shell 1001 has a geometry (e.g., consistentthickness) that renders it easy to manufacture but that provides onlygeneric light distribution. A silicone optic 1002 may be used to enhanceand customize that distribution. More specifically, silicone may bemolded or cast on the outside or underside of the pre-formed optic shellto add shape to the lens so as to achieve the desired lightdistribution. As shown in FIG. 11, structures or mechanical featuressuch as voids 1003 (e.g., grooves, holes, etc.) may be provided in theflange on the optic shell so that, when the silicone is molded or caston the shell 1001, it fills the voids 1003 and thus mechanicallyinterlocks the shell and silicone layers together with the firstmaterial 1001.

The shell 1001 may be formed of glass and the silicone optic 1002 may bemolded on the underside of the glass directly over the light source 604or internal to the luminaire such that the silicone is not exposed tothe outside of the luminaire. In this way, the outer shell of glasscreates a clean smooth surface that is hard and resistant to scratchingand other normal wear as well as dirt build-up. The internal layer ofsilicone provides precise and sharp inner optical shapes with no draft(i.e., taper with respect to a parting line) and some slight undercutsto control the optics to a higher level of optical efficiency over solidglass or plastic parts. As shown in FIG. 11, one or more grooves 1003may be provided for the purpose of ensuring mechanical attachmentbetween shell 1001 and silicone optic 1002 where the silicone fills thegrooves to interlock the silicone optic 1002 with the existing opticshell 1001.

Silicone can be molded, cast, or extruded directly onto one or morefirst materials where the first materials are, for example, opticalplastic grade acrylic poly(methyl methacrylate) (PMMA), polycarbonate(PC), or glass. The index of refraction is different for each material.As the materials are bonded, each pair of materials creates an internalsurface at the interface of the different materials not visible to anunaided human eye. There is an interstitial interface at the internalsurface, and the interstitial interface is continuous between thedifferent materials such that there is no free air between the twomaterials. The interstitial interface refracts light with fewer lossesand, consequently, higher performance than if an air gap exists betweenmaterials. The elimination of the air gap between materials ensures thatlosses are minimized because the elimination of the air gap causes morelight to pass through the interstitial interface compared to lightreflected in unwanted directions due to reflections created at theinterface of a lens and an air gap. The elimination of the air gapyields an increase in performance efficiency of 30% to 50% compared toknown reflection losses with air to surface reflections. The performancegains are due to (1) the interstitial interface and (2) the additionalfine detail (small-scale features) of the silicone optical structurecompared to glass. The size and geometry of glass structure is limiteddue to the molding temperatures of glass which result in fine detailsbreaking off during the cooling process. Further, glass requires steeltools, which, if built with the fine details seen in the silicone opticsherein, will fracture in the molding process due to the high temperatureof the molten glass.

The speed of light depends on the material properties of the objectthrough which the light is travelling (i.e., air, water, glass, plastic,etc.) and all materials have an index of refraction (n) to define thespeed at which light passes through the respective material. Inaddition, based on the index of refraction and the associated speed, theangle of incidence (i.e., the angle with respect to the normal directionof the surface of the object through which the light passes) changes aslight moves from one material to another (i.e., from air into a lens).In other words, the travel direction of light “bends” as it passes froma first material to a second material. Further, the amount of bendingthat occurs when the light enters the second material is proportional tothe ratio of the indices of refraction of the first and second materialssuch that less bending will occur if the two materials have similarindices of refraction. Because, as described above, the interstitialinterface eliminates any air gap between the silicone and the adjacentcomponent to which it is bonded, the light bending that occurs is easierto control and calculate resulting in increased optical performance. Forexample, there is only one bending occurrence (lens-to-silicone) whereasa configuration with an air gap would result in two bending occurrences(lens-to-air and air-to-silicone). Furthermore, the materials can beselected to ensure similar indices of refraction to limit the amount ofbending to better control and predict resultant light output andmaximize efficiency.

Based on the respective indices of refraction, a critical angle can becalculated for the interface between two known materials. When light isincident on a surface of a material, the light can pass entirely throughthe material (either at the angle of incidence or at a refracted angle),part of the light can pass through the material and part of the lightcan be reflected at the surface, or, if the angle of incidence equals oris greater than the critical angle, all of the light can be reflected bythe material (called total internal reflection or TIR). The criticalangle is the minimum threshold angle with respect to the axis normal tothe surface of a material at which light incident on the materialsurface will be totally internally reflected by the material (i.e., willnot pass through the material but be entirely reflected by thematerial). The exact value of the critical angle depends upon thematerial used for the optic and its index of refraction. Differentcombinations of materials have different critical angles.

Total internal reflection (TIR) limits the degree to which light can berefracted or bent by an optic and thus limits the angular range at whichlight can exit an optic. The hybrid optics described herein can be usedto bend light more often and collectively to a greater extent thantraditional optics to achieve light emission from the optic within awider angular range. More specifically and as described above, the useof the interstitial interface allows two materials to be layered(without an air gap in between) such that light can be preciselycontrolled and provides three opportunities to bend the light including(1) geometric features at the entry surface of the first material, (2)the interstitial interface between the first material and the secondmaterial, and (3) geometric features at the exit surface of the secondmaterial. The collective angle at which the light is refracted or bentby these three surfaces can exceed the critical angle while avoidingTIR. Of course, additional layers can be added to the optic, which wouldincrease the number of opportunities for bending of light. Accordingly,because of the interstitial interface (or interstitial interfaces if thelens has more than two layers) and depending on the geometric featuresand materials chosen for the lens, lenses can be built that are capableof refracting light from any angle from 0° (parallel to the normaldirection) to approximately 90° (perpendicular to the normal direction)including angles greater than the critical angle.

Place Bonding Methods

Co-molded optics can be made from any material suitable for opticaltransfer or reflection including but not limited to plastic, glass,silicone, metal, or film and can be bonded to a second material using abonding substrate material to permanently adhere the optic structure toa second optical structure (constructed from the second material) toenhance optical properties.

One example of an assembled light fixture including a place bondedsilicone optic 1400 is shown in FIG. 16. The light source 604 isattached to a heat sink 1603 with an adjacent reflector 1602 such thatlight is directed into the pre-molded or pre-cast silicone optic 1400before finally passing through the second material 1501. The efficiencyof the pre-molded or pre-cast silicone optic 1400 combined withreflector 1602 allows dimension H to be approximately 1 inch.Conventional light fixture arrangements often require approximately 6inches for dimension H. Accordingly, the silicone optics describedherein may help reduce weight, physical dimensions, and inefficienciesassociated with traditional lighting fixtures.

A method of “place bonding” where pre-molded or pre-cast silicone opticsare arranged adjacent to other optical or mechanical materials such asdirectly onto a second material (i.e., a sheet of glass) typically usedon luminaires as a lens or reflector cover to keep the luminaireinterior sealed (i.e., to ensure that the interior of the luminaire isfree of contaminants such as dirt and rainwater). It is possible todirectly mold silicone optics onto glass using a standard injectionmolding machine, but the costs associated with standard over moldtooling are high and such methods are time consuming because a tool mustbe designed and manufactured specifically for each application. From abusiness perspective, these methods are undesirable because it isdifficult to amortize or recoup the cost of the tool during typicalshort life product runs. Accordingly, one solution is to employ a methodusing a “place bonding” template die that is placed over the secondmaterial. Pre-molded or pre-cast optics can be placed into the dieopenings by hand or using pick and place robotic system. To seal thecomponents, a heat cured silicone optical material may be used to bondthe pre-cast/pre-molded optic 1400 to the second material 1501. The heatcured silicone optical material may be a room temperature vulcanizing(RTV) sealant or a liquid silicone rubber (LSR). One example of apre-molded or pre-cast silicone optic 1400 is shown in FIGS. 14A-17.Once the optic 1400 has been placed with the RTV or LSR bonding material1502, the complete part 1500 will be inserted in a thermal curing ovento cure the bonding material 1502 (see FIG. 15). A lehr (i.e., acontinuous furnace that is a long oven or kiln with a conveyor belt)could also be used to cure the bonding material 1502.

Optic 1400 typically may be up to 24 inches wide (i.e., in theY-direction in FIGS. 14A and 14B) with a continuous length or anypractical length (i.e., in the X-direction in FIGS. 14A and 14B).Further, modular sizes from 1 to 12 inches, 12 to 24 inches, 24 to 48inches, and 48 inches or longer for continuous run luminaires.

The foregoing is provided for purposes of illustrating, explaining, anddescribing embodiments of the present invention. Further modificationsand adaptations to these embodiments will be apparent to those skilledin the art and may be made without departing from the scope or spirit ofthe invention. Different arrangements of the components depicted in thedrawings or described above, as well as components and steps not shownor described are possible. Similarly, some features and subcombinationsare useful and may be employed without reference to other features andsubcombinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentsare possible. Accordingly, the present invention is not limited to theembodiments described above or depicted in the drawings, and variousembodiments and modifications can be made without departing from thescope of the invention.

What is claimed is:
 1. An optical component configured to direct lightemitted from a light source, the optical component comprising: at leastone pre-formed component comprising a first material and having alight-emitting region through which light passes through the at leastone pre-formed component, wherein the light-emitting region is of aconstant thickness and comprises an outermost surface and an undersidethat forms an approximately semi-cylindrical recess; and a customizedoptic formed of a second material and provided on and in intimatecontact with the outermost surface of the light-emitting region suchthat a portion of the customized optic at least partially covers theoutermost surface, wherein: the customized optic comprises varyingthickness; the approximately semi-cylindrical recess is adjacent to thelight source; and the first material is different from the secondmaterial and wherein the second material is silicone.
 2. The opticalcomponent of claim 1, wherein the at least one pre-formed componentcomprises at least one of glass and plastic.
 3. The optical component ofclaim 1, wherein the at least one pre-formed component comprises: afirst pre-formed component comprising the approximately semi-cylindricalrecess and an outer surface; and a second pre-formed componentcomprising the outermost surface and an inner surface provided on and inintimate contact with the outer surface.
 4. The optical component ofclaim 3, wherein the first pre-formed component comprises a phosphorlens and the second pre-formed component comprises a diffuser lens. 5.The optical component of claim 1, further comprising at least onemounting bracket attached to an end surface of the at least onepre-formed component, wherein the at least one mounting bracketcomprises an exterior surface that is approximately aligned with theoutermost surface of the at least one pre-formed component.
 6. Theoptical component of claim 5, wherein the exterior surface comprises agroove and the second material of the customized optic fills the groove.7. The optical component of claim 1, wherein: the customized opticcomprises a first thickness aligned with a center of the approximatelysemi-cylindrical recess; the customized optic comprises a secondthickness offset in a lateral direction from the center of theapproximately semi-cylindrical recess; and the second thickness isgreater than the first thickness.
 8. The optical component of claim 7,wherein the second thickness is at least double the first thickness. 9.An optical component configured to direct light emitted from a lightsource, the optical component comprising: at least one pre-formedcomponent of a first material; and a customized optic formed of a secondmaterial and encapsulating at least a portion of the at least onepre-formed component, wherein the customized optic has a light-emittingregion through which light passes through the customized optic, whereinthe light-emitting region has a varying thickness and comprises anoutermost surface and an underside that forms a flat portion and arecess configured to receive the light source, wherein the firstmaterial is different from the second material and wherein the secondmaterial is silicone.
 10. The optical component of claim 9, wherein theat least one pre-formed component comprises two pre-formed componentsarranged on opposite sides of the recess of the customized optic. 11.The optical component of claim 9, wherein the at least one pre-formedcomponent comprises a reflector at least partially embedded within thecustomized optic and disposed adjacent to the recess so as to directlight emitted by the light source.
 12. The optical component of claim11, wherein the recess extends along a length of the customized opticand wherein the reflector is offset from and extends approximatelyparallel to the recess.
 13. The optical component of claim 9, whereinthe at least one pre-formed component comprises a first portion that isplanar and a second portion that is attached to and arranged at anon-parallel angle to the first portion, wherein the second portioncomprises at least one of a planar reflective surface and a curvedreflective surface.
 14. The optical component of claim 13, wherein theat least one pre-formed component further comprises a flange extendingfrom the first portion, where the flange is approximately parallel tothe flat portion of the underside of the customized optic.
 15. Theoptical component of claim 14, wherein at least a portion of the flangeextends outside of the customized optic and comprises a surface that isapproximately coplanar with the flat portion of the underside of thecustomized optic.
 16. The optical component of claim 13, wherein thefirst portion of the at least one pre-formed component comprises aplurality of apertures encapsulated within the customized optic suchthat, when the customized optic is created, the silicone flows into theplurality of apertures to mechanically interlock the customized opticand the at least one pre-formed component.
 17. An optical componentconfigured to direct light emitted from a light source, the opticalcomponent comprising: a pre-formed component of a first material andhaving a light-emitting region through which light passes, wherein thelight-emitting region is of a constant thickness and comprises an uppersurface and a lower surface; and a customized optic formed of a secondmaterial and provided on the lower surface of the light-emitting regionsuch that a portion of the customized optic at least partially coversthe lower surface, wherein: the customized optic comprises varyingthickness; the customized optic is disposed between the pre-formedcomponent and the light source; and the first material is different fromthe second material and wherein the second material is silicone.
 18. Theoptical component of claim 17, wherein at least a portion of thecustomized optic is in intimate contact with the lower surface of thelight-emitting region of the pre-formed component.
 19. The opticalcomponent of claim 17, further comprising a layer of silicone opticalmaterial disposed between and for attaching the customized optic and thepre-formed component, wherein the first material comprises glass. 20.The optical component of claim 17, wherein the customized opticcomprises a cross-sectional shape comprising a portion having a circularprotrusion with a constant radius.
 21. The optical component of claim17, wherein the customized optic comprises a cross-sectional shapecomprising a plurality of wedge-shaped protrusions and wherein theplurality of wedge-shaped protrusions extend away from the pre-formedcomponent.
 22. The optical component of claim 21, wherein the pluralityof wedge-shaped protrusions have varying heights such that the heightsdecrease when moving toward a center of a width of the customized optic,wherein each low point between adjacent wedge-shaped protrusions isapproximately equidistant from the pre-formed component.
 23. The opticalcomponent of claim 21, wherein: the cross-sectional shape furthercomprises a portion having a circular protrusion; the plurality ofwedge-shaped protrusions are arranged symmetrically about the circularprotrusion; and the circular protrusion has a constant radius andextends a greater distance from the pre-formed component compared to amajority of the plurality of wedge-shaped protrusions.
 24. The opticalcomponent of claim 17, further comprising a separate reflector adjacentto the light source such that the separate reflector extends toward thecustomized optic such that the separate reflector and the customizedoptic are detached from one another.